TECHNICAL TRAINING

SALES DIVISION

PRESENTATION OF THE MACHINE

rf :.JET.010.02/2003.GB

CONTENTS
CHARACTERISTICS..... 5 Engine..... 5 Dimensions and weight.... CC ENGINES..... cc 2-stroke TSDI liquid cooled engine... 6 Description..... 7 Separate lubrication.... 7 Cooling..... 7 CATALYTIC EXHAUST..... 8 Composition of the catalytic exhaust system:.... 8 FUNCTIONING OF THE CATALYTIC CONVERTER EXHAUST... 8 Definition..... 8 INJECTION SYSTEMS / TSDI IGNITION... 9 Introduction.... 9 SYSTEM COMPONENTS.... 10 Functioning principle.... 10 PRESENTATION OF THE 2 STROKE INJECTION SYSTEM... 11 DIAGNOSTIC..... 12 Warning..... 12 Fault processing principle.... 12 Self-diagnostic principle..... CC ENGINES.... cc 4-stroke EFI liquid cooled engine.... 13 Description..... 14 Lubrication..... 14 Cooling...... 14 Cooling system functioning principle.... 14 INTRODUCTION..... 15 ADVANTAGES OF THE INJECTION SYSTEM... 15 Fuel injector..... 15 INJECTION SYSTEM / EFI IGNITION... 16 Reminder of operation.... 16 FRAME..... 17 Frame..... 17 Suspension.... 18 Tyres..... 18 Suspension.... 19 Tyres..... 19 BRAKES...... 20 Reminder of functioning of the different braking systems... 20 ABS/PBS hydraulic braking system.... 21 ABS/PBS SYSTEM SYNOPTICS... 22 BODY PANELS..... 23 ELECTRICITY..... 25 Functioning principle of the 50 cc starter and lighting circuits... cc ignition on or engine running.... cc starting function.... 27 Direction indicator functioning principle (125 cc)... 28 Hazard warning lights with ignition on (125 cc)... 29
TRAINING MANUAL: JET FORCE: Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

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CONTENTS Hazard warning lights without ignition on (125 cc)... 30 Functioning principle of the ABS/PBS system (125 cc)... 31 ABS/PBS ELYSTAR 125cc.... 32 TRANSPONDER IMMOBILISER.... 33 System programming.... 33 Reminder of the key memory procedure... 33 Key memory check..... 33 Additional information..... 33 Synoptics..... 34 INSTRUMENT CLUSTER..... 36 Description..... 36 Instrument cluster self-diagnostic when ignition is turned on... 36 Description of the multi-function display... 37 MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS.. 37 Changing the distance unit.... 37 Tripmeter Total/Daily display.... 38 Daily Km reset..... 38 Time setting..... 38 Maintenance reset..... 39 Fuel gauge self-diagnostic.... 39 Gauge functioning (8s timer).... 39 LOCATION OF COMPONENTS.... cc..... cc..... 41 SPECIAL TOOLING..... 42

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CHARACTERISTICS
CHARACTERISTICS Engine 50 cm3 Type Cooling Bore x stroke Cubic capacity Max. power output Max. torque at Fuel system Lubrication Transmission Clutch Spark plug Exhaust Single cylinder 2-stroke direct injection Liquid 39.9 x 39.8 mm 49.9 cc 3.75 kW at 7500 rpm 57 x 48.9 mm 124.8 cc 9.2 kW at 8750 rpm 125 cm3 Single cylinder 4-stroke indirect injection
6500 rpm 7250 rpm Direct electronic injection Indirect electronic injection (EFI) (TSDI) Electric oil pump Trochoidal pump 2 variable pulleys and Vee belt Centrifugal automatic NGK CPR8E NGK CR7EB Catalytic Non-catalytic
Dimensions and weight Overall length Width at handlebar Height with rear view mirror Wheelbase Saddle height: Unladen weight 1914 mm 740 mm mm 820 mm 115 kg mm 845 mm 149 kg 1918 mm

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50 CC ENGINES
50 CC ENGINES 50 cc 2-stroke TSDI liquid cooled engine 45 km/h version Sport version Unlimited version (registered)

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Description HL1 engine marking
Separate lubrication 1.2 l tank capacity

Cooling 1.2 l capacity

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CATALYTIC EXHAUST

CATALYTIC EXHAUST Composition of the catalytic exhaust system: The catalytic exhaust system is distinguished by the fitting of a catalyser cone just after the exhaust inlet cone. All the exhaust gases are fed through the catalyser cone.
1. Exhaust pipe 2. Heat insulation 3. Catalyser cone FUNCTIONING OF THE CATALYTIC CONVERTER EXHAUST Definition The catalyser is a block used to facilitate and acceleration chemical reactions without being modified itself Composition of the catalytic block The catalytic block is composed of a metal grid, impregnated with precious metals, rolled inside a steel tube forming a honeycomb.

1. 2. 3. 4.

Metal grid Steel tube Honeycomb Impregnation with precious metals (Platinum, palladium, rhodium, etc.)

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INJECTION SYSTEMS / TSDI IGNITION
INJECTION SYSTEMS / TSDI IGNITION Introduction Of the throttle angle / engine speed type, the SYNERJECT system was developed for the following applications: Monopoint sequential injection Static timing The system basic principle consists in measuring the engine speed and load ( throttle opening ) in order to determine the optimum quantity of fuel injected This system is used on the JET FORCE 50 scooter and requires NO ADJUSTMENT (Ditto Looxor and Elystar 50 cc).
Cylinder head Petrol injector Air injector Spark plug

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SYSTEM COMPONENTS
SYSTEM COMPONENTS Functioning principle

1. 2. 3. 4. 5. 6.

Crank assembly Compressor Throttle unit Spark plug Lubrication system Feed rail a / petrol injector b / air injector c/ petrol pressure regulator

A. B. C.

Fuel inlet Fuel return Pressurised air inlet

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PRESENTATION OF THE 2-STROKE INJECTION SYSTEM
PRESENTATION OF THE 2 STROKE INJECTION SYSTEM
Fuel system 1. Fuel tank 2. Fuel pump 3. Pressure regulator Ignition system: 4. Coil and suppressor 5. Resistive spark plug
Injection system 6. Petrol injector 7. Air injector Lubrication system 8. Oil tank 9. Oil pump
Compressed air circuit 10. Compressor Transponder circuit 11. Immobiliser module 12. Transponder

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DIAGNOSTIC
DIAGNOSTIC Warning A LED comes on on the instrument cluster to warn the rider of a fault on the injection and ignition system ELECTRICS Fault processing principle Three priority levels 1 - serious safety fault: fault memorised in ECU and LED stays on 2 - serious fault: fault memorised in ECU and LED flashes 3 - minor fault: fault memorised in the ECU without lighting the warning light Note: When the ignition is turned on, the LED stays on to check it is functioning correctly Self-diagnostic principle Warning light on inst. cluster

Injection ECU

INPUTS

Microprocessor

OUTPUTS
Injection Ignition System

Fault memory

Dialogue with the tester

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125 CC ENGINES
125 CC ENGINES 125 cc 4-stroke EFI liquid cooled engine Naturally aspirated version Turbo version (compressor)

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Description FD5 engine markings Lubrication 1.25 l capacity Cooling 1.5 l capacity
Cooling system functioning principle
Battery Ignition switch Fan Heat switch

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INTRODUCTION Of the throttle angle / engine speed type, the EFI system was developed for the following applications: Monopoint sequential injection Static timing The system basic principle consists in measuring the engine speed and load ( throttle opening ) in order to determine the optimum quantity of fuel injected This system is used on the JET FORCE 125 scooter and requires NO ADJUSTMENT (Ditto Elystar cc) ADVANTAGES OF THE INJECTION SYSTEM Peugeot Motocycles has developed a new generation of engines. Cleaner, more reliable, more economical, these engines comply with the most stringent emission control standards, whilst maintaining a very high level of performance. There are many advantages : - Reduction in polluting emissions - Reduction in fuel consumption - Improved rider comfort Fuel injector The injectors are of the electro-magnetically operated single-jet type The ECU electrical pulses generate a magnetic field in the magnet winding, the core is attracted, the injector plate raised off its seat and releases the pressurised fuel upline of the inlet valve

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INJECTION SYSTEM / EFI IGNITION
INJECTION SYSTEM / EFI IGNITION Reminder of operation
1. ECU 2. Battery Fuel system 3. Fuel tank 4. Fuel pump 5. Pressure regulator Ignition system: 6. HT coil 7. Resistive spark plug and suppressor
Transponder circuit 8. Transponder module 9. Transponder Injection system 10. Petrol injector 11. Idle control valve 12. Air pressure and air temperature sensor Diagnostic circuit 13. Injection diagnostic lamp 14. Transponder diagnostic lamp 15. Diagnostic plug

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FRAME Frame
Steel wrap-round frame (DIRECT PERIMETRIC FRAME - DPF)

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50 CC FRAME
Suspension 50 cm3 Front suspension: Travel Rear suspension Travel 32 mm hydraulic telescopic fork 85 mm Central hydraulic shock absorber 95 mm
Tyres Front wheel Front tyre Front tyre pressure Rear wheel Rear tyre Rear tyre pressure 13-inch alloy 130/60 - bar 13-inch alloy 130/60 - 13 2,2 bar

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125 CC FRAME
Suspension 125 cm3 Front suspension Travel Rear suspension Travel 36 mm hydraulic telescopic fork 95 mm Central hydraulic shock absorber 90 mm
Tyres Front wheel Front tyre Front tyre pressure Rear wheel Rear tyre Rear tyre pressure 13-inch alloy 130/60 - bar 13-inch alloy 140/60 - 13 2,2 bar

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BRAKES
BRAKES Reminder of functioning of the different braking systems Conventional hydraulic system
SBC integral hydraulic braking system
SBC2 integral hydraulic braking system

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ABS/PBS hydraulic braking system

1. 2. 3. 4. 5.

Braking control unit Right-hand brake master cylinder (emergency brake) Front brake caliper Left-hand brake master cylinder (integral brake) Rear brake caliper

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ABS/PBS SYSTEM SYNOPTICS

RH brake lever contactor

Hydraulic pump

ABS/PBS ECU

Brake light

Front wheel speed sensor

Software: Manages system operation
Battery voltage Vehicle coding (PIN code)
Calibration: Values specific to machine (mapping)
Regulation solenoid valve

Main relay

Starter relay

Instrument cluster

Diagnostic plug

Diagnostic light

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BODY PANELS BODY PANELS

TRAINING MANUAL: JET FORCE Reproduction or translation, even partial, is forbidden without the written consent of Peugeot Motocycles

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BODY PANELS
LEGSHIELD TOP PANEL (1) FOOTBOARDS (5) RIDER SADDLE (8) PASSENGER SADDLE AND GRAB HANDLE (15)
HANDLBAR FRONT FAIRING (2)
FRONT LOWER LEGSHIELDS (4)

TUNNELS (6)

STORAGE COMPARTMENT (9)

BATTERY COVER (16)

HANDLEBAR REAR FAIRING (3)
MUDGUARD AND FORK GUARD (12)

BELLYPAN (7)

FUEL TANK FAIRING (10)
REAR FAIRING AND IMMOBILISER UNIT (17)

MUDGUARD (13)

LEGSHIELD REAR PANEL (11)

MUDFLAP AND NUMBER PLATE PANEL (14)
STORAGE COMPARTMENT TRIM PANELS (18)

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ELECTRICITY
ELECTRICITY Functioning principle of the 50 cc starter and lighting circuits
1. Battery 2. Ignition switch 3. Starter button 4. Lighting control 5. Rear light 6. Instrument cluster 7. Brake light 8. High beam 9. Dip beam 10. Sidelight 11. Lighting relay 12. Starter motor relay 13. Starter motor 14. Brake light switch
BA JN-BE JN-VE MR NR RG RG-NR VE VI
White Yellow-Blue Yellow-Green Brown Black Red Red-Black Green Mauve

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50 cc ignition on or engine running
The lighting relay (11) is powered when the ignition is on via terminals 1 and 3 Over terminal 2 of the relay, the control coil is earthed through the starter motor (13) The power circuit, via relay terminal 5 powers: - The rear and front sidelights - The number plate light (50cc IL and 125cc) - The instrument cluster lighting - Power supply to the Dip/Full Beam control (4) and the headlight flasher for the 125 cc

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50 cc starting function
Press starter button (3): Pressing the starter button (3) earths the starter relay winding (12) which then powers: - The starter motor - Terminal 2 of the lighting relay (11) The potential on the coil two terminals is the same (12 V): - the magnetic field disappears - the relay blade opens - the lighting circuit is no longer powered Note: All of the battery power will be used by the starter motor Without pressing the starter button (3): The magnetic field in the starter relay coil (12) disappears the power circuit opens: - Terminal 2 on the lighting relay is earthed through the starter motor - The lighting circuit is powered

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Direction indicator functioning principle (125 cc)
Direction indicator function

1. 2. 3. 4. 5. 6. 7. 8.

Battery Ignition switch Instrument cluster Direction indicator switch Hazard warning lights switch Right direction indicator Left direction indicator Direction indicator unit

BA-NR BC JN-BE OR RG RG-NR VE VI
White-Black Light blue Yellow-Blue Orange Red Red-Black Green Mauve

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Hazard warning lights with ignition on (125 cc)

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Hazard warning lights without ignition on (125 cc)

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Functioning principle of the ABS/PBS system (125 cc)
1. Battery 2. Ignition switch 3. Module main relay 4. Starter motor relay 5. RH brake contactor 6. LH brake contactor 7. Instrument cluster 8. Machine speed sensor 9. Control unit 10. 25A fuse 11. 15A fuse 12. Brake light 13. Diagnostic plug

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ABS/PBS ELYSTAR 125cc

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TRANSPONDER IMMOBILISER
TRANSPONDER IMMOBILISER Precautions: Check that the diagnostic plug jumper is fitted. The jumper provides the link between the immobiliser module and the injection/ignition ECU, and is essential to be able to start the engine If the jumper is not fitted, the transponder LED diagnostic is always the same (no link between the immobiliser and the ECU) Note: Fitting of a 5 k resistive suppressor along with a resistive spark plug is essential for the proper functioning of the engine System programming The machine is supplied with a red key (master) and a black key The system is programmed in the factory It is possible to program up to 7 black keys The key memory procedure is the same as the AEC400 and ACI100 system Reminder of the key memory procedure 1. Using the red key, set the ignition to on, and when the LED lights, turn off the ignition 2. Within a maximum of 15 seconds of cutting off the ignition with the red key, turn on the ignition with the black key, and when the LED comes on turn off the ignition (repeat the operation for each black key to be memorised (maximum of 7 black keys)) 3. Within a maximum of 15 seconds of turning off the ignition with the last key memorised, turn on the ignition with the red key, and when the LED comes on, turn off the ignition Key memory check Using the red key, turn on the ignition, the LED on the instrument panel comes on for 0.5 seconds and flashes a number of times. The number of flashes indicates the number of keys memorised, including the red key
Additional information Before carrying out any work on the transponder immobiliser, have the machine red key and black key to hand If the engine will not start, a first diagnostic may be carried out using the LED before checking the other parts of the ignition system
Note: Do not remove the diagnostic plug jumper In case of a fault, do not use an immobiliser module or ECU from another machine to carry out tests. The keys, immobiliser module and ECU programmed on another machine form an assembly, are linked by a code and must under no circumstances be separated

Important : If an ECU is changed without memorising the keys, do not turn on the ignition more than 16 times if the diagnostic jumper is disconnected as beyond this number, the ECU immobiliser function is erased.

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TRANSPONDER IMMOBILISER Synoptics

Assembly correct

Cut between the immobiliser module and the ECU
Cut between the antenna and the immobiliser unit or no transponder in they key
Wrong key or immobiliser module from another machine

Blank immobiliser module

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Blank ECU (starting possible with red key)
Immobiliser module and ECU blank
Programmed immobiliser module and key from another machine
Blank ECU, with 16 memorised switch on without diagnostic plug loop

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INSTRUMENT CLUSTER
INSTRUMENT CLUSTER Description
1. Multi-function display 2. Rev counter 3. Speedometer 4. Engine temperature gauge 5. Control button 6. Injection system diagnostic warning light 7. Transponder immobiliser dissuasion light 8. ABS/PBS system diagnostic light 9. Headlight warning light 10. Oil low level warning light 11. Direction indicator warning light 12. Battery charge warning light
Instrument cluster self-diagnostic when ignition is turned on Different functioning tests are carried out automatically for 5 seconds : - Display of all of the multi-function display items (1) and the speed (3) - Lighting of all the warning lights (except ABS/PBS depending on version) - Test of rev counter stepper motors (2) and engine temperature (4) giving one sweep of the needles and zero reset where necessary

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Description of the multi-function display
13. Odomtre (totaliseur ou journalier) 14. Indication de l'affichage de l'odomtre journalier 15. Indication de l'unit utilise par l'odomtre 16. Horloge 17. Indicateur de maintenance (symbole "cl") 18. Jauge carburant
MULTI-FUNCTION DISPLAY FUNCTIONS AND SETTINGS Changing the distance unit
- Ignition off -Press button and hold down -Turn on the ignition -Release the button -Press for <3s to select Km/Miles -Turn off ignition to confirm

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Tripmeter Total/Daily display
- Turn on the ignition -Press and release the button to select the function required Daily Km reset -Hold down the button for >5s Time setting
The time can only be set in the tripmeter total position - Ignition on, press the button (5) until the time flashes - Set the time by successive pushes on the control button - Press the control button to confirm the hour, the minutes figure flashes - Proceed in the same way to set the minutes - Press the control button for more than 3 seconds to confirm the time

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Maintenance reset Every 5000 km a spanner symbol appears informing the rider that his machine is due for service After servicing the machine, erase the symbol as follows:
- Ignition off - Press button and hold down -Turn on the ignition (only the spanner appears and flashes) - Press for >5s to erase the symbol Fuel gauge self-diagnostic If the fuel system is cut off from the fuel gauge, when the ignition is turned on, the 8 LEDs light one after the other Gauge functioning (8s timer) 8 LEDs represent a full tank (10 ohms) 2 LEDs flash (75 ohms) 1 LED flashes (98 ohms) 8 LEDs flash (R> 87 ohms) means an empty tank

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LOCATION OF COMPONENTS
LOCATION OF COMPONENTS 50 cc
1. Injection ECU 2. Throttle unit 3. Engine position and speed sensor 4. Temperature sensor 5. Battery 6. Fuel injector 7. Air injector 8. Ignition coil 9. Immobiliser module 10. Fuel pump
11. Oil pump 12. Diagnostic light 13. Diagnostic plug 14. Air compressor 15. Fuses 16. Voltage regulator 17. Horn 18. Saddle lock 19. Starter / lighting relay

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125 cc
1. Injection ECU 2. Throttle unit 3. Engine position and speed sensor 4. Temperature sensor 5. Air pressure and air temperature sensor 6. Battery 7. Fuel injector 8. Idle control valve 9. Ignition coil 10. Immobiliser module 11. Fuel pump
12. Diagnostic light 13. Diagnostic plug 14. Fuel pump relay/ABS relay/light relay/Fuse 25A 15. Heat switch 16. Motor-driven fan 17. Fuse 15A/starter relay 18. Voltage regulator 19. Horn 20. Saddle lock 21. ABS/PBS module 22. Machine speed sensor

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SPECIAL TOOLING
. Tool N 756717 Description Engine mount adapter 125 cc Used with. Tool N 755990 Description Diagnostic tool update software Used with Computer 755807 755878

750539

Tie-wrap pliers

755806

Cartridge Europe

755996

Pipe clamp

755807 Cartridge Export

755878

755986

air injector setting tool 50 cc
Diagnostic tool (game boy color)

755989

air injector drift 50 cc

756714 replaces 755878

Diagnostic tool (game boy advance)

755806 755807

replaces 756076

Tank gauge spanner

756017
50 cc fuel injector power supply harness

756716 replaces 755056

Tank ring spanner

756449

ABS/PBS interface cable for diagnostic tool 125 cc

TRAINING MANUAL :

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Tool N 756607

Description Fork seal fitting tool 125 cc

Used with

756608
Fork seal fitting tool 50 cc

756668

Crank assembly lip seal tool 50 cc

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